Bicycle frame with battery mount

ABSTRACT

A bicycle comprises front and rear wheels, a frame supported on the front and rear wheels and including a frame mount, and a battery including a battery mount engaged with the frame mount. One of the battery mount and the frame mount includes a depression and the other of the battery mount and the frame mount includes a boss positioned in the depression. Preferably, depression comprises a slot, and the slot can include a resilient material to securely hold the boss. The boss can comprise an eccentric boss. Preferably, the battery mount is positioned adjacent one end of the battery, and an opposite end of the battery includes an opening. In this embodiment, the bicycle further comprises a mounting pin positioned through the opening and through a portion of the frame to secure the opposite end of the battery to the frame.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 15/816,181, filed on Nov. 17, 2017, and a continuation ofco-pending U.S. patent application Ser. No. 15/816,177, filed on Nov.17, 2017, and a continuation of co-pending U.S. patent application Ser.No. 15/816,162, filed on Nov. 17, 2017, each of which is a continuationof U.S. patent application Ser. No. 15/482,949, filed on Apr. 10, 2017,which is a continuation of U.S. patent application Ser. No. 14/752,313,filed on Jun. 26, 2015, now U.S. Pat. No. 9,616,966, the entire contentsof all of which are incorporated herein by reference.

BACKGROUND

The present invention relates to bicycle frames and specifically to abicycle frame that is adapted to support a battery.

It is known to provide a bicycle with an electric motor and battery inorder to supplement the pedaling power provided by the user. Suchelectric motors and batteries can be secured to or incorporated into thebicycle frame.

SUMMARY

The present invention provides a bicycle comprising front and rearwheels, a frame supported on the front and rear wheels and including aframe mount, and a battery including a battery mount engaged with theframe mount. One of the battery mount and the frame mount includes adepression and the other of the battery mount and the frame mountincludes a boss positioned in the depression. The depression is designedto receive the boss at multiple locations to accommodate slightdifferences in a length of the battery. Preferably, depression comprisesa slot, and the slot can include a resilient material to securely holdthe boss.

In one embodiment, the boss comprises an eccentric boss. For example,the boss can have a first boss width that is insertable into thedepression/slot when the battery is in a first orientation, and the bosscan further have a second boss width larger than the first boss widthand creating an interference fit.

In another embodiment, the battery mount is positioned adjacent one endof the battery, and an opposite end of the battery includes an opening.In this embodiment, the bicycle further comprises a mounting pinpositioned through the opening and through a portion of the frame tosecure the opposite end of the battery to the frame. The distance fromthe opening to the battery mount defines the length of the battery.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a bicycle incorporating features of the presentinvention.

FIG. 2 is a perspective view of a bicycle frame assembly of the bicycleshown in FIG. 1.

FIG. 3 is a partially exploded view of the bicycle frame assembly ofFIG. 2.

FIG. 4 is an enlarged perspective view of a lower portion of a frame ofthe bicycle of FIG. 1.

FIG. 5 is a right side view of a lower portion of the frame of FIG. 4.

FIG. 6 is a section view taken along line 6-6 in FIG. 4.

FIG. 7 is a perspective view of the battery in a partially-attachedposition.

FIG. 8 is a perspective view of the battery in a fully-attachedposition.

FIG. 9 is a section view taken along line 9-9 of FIG. 7 showing thelower battery mount engaged with the lower frame mount with the batteryin the partially-attached position of FIG. 7.

FIG. 10 is a section view taken along line 10-10 of FIG. 8 with thebattery in the fully-attached position of FIG. 8.

FIG. 11 is an enlarged perspective view of an upper frame mount prior toinstallation of the battery.

FIG. 12 is the perspective view of FIG. 11 with the battery in thefully-attached position of FIG. 8.

FIG. 13 is an enlarged view of a battery control panel on the battery.

FIG. 14 is an enlarged perspective view of a battery connector on thebattery.

FIG. 15 is an enlarged perspective view of a speed sensor.

FIG. 16 is an exploded view of a right motor cover with an integratedcable channel.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

FIGS. 1-3 illustrate a bicycle 20 embodying the present invention. Theillustrated bicycle 20 includes a front wheel 22 and a rear wheel 24that cooperatively define a central plane 26 and forward and rearwarddirections. A front fork 28 is supported by the front wheel 22, and aframe 30 is supported by the front fork 28 and the rear wheel 24. Theillustrated frame 30 includes a head tube 32 rotationally coupled to thefront fork 28, a down tube 34 extending downward and rearward from thehead tube 32, a top tube 36 extending rearward from the head tube 32, aseat tube 38 extending downward from the top tube 36, and a motor mount40 connecting the down tube 34 and the seat tube 38. The frame 30further comprises a rear suspension assembly 42 including chainstays 44,rear wheel mounts 46, seat stays 48, and a rear shock 50, the functionsof which are well known in the art.

The illustrated bicycle 20 further includes an electric motor 52 adaptedto provide power to the bicycle 20. The illustrated electric motor 52includes three mounting studs 54 for securing the electric motor 52 tothe frame 30 via mounting nuts 55. The electric motor 52 furtherincludes a drive shaft 56 connected to left and right cranks 58 that areadapted to receive corresponding pedals 59 that facilitate pedaling ofthe bicycle 20 by a user. Power is provided to the electric motor 52 viaa battery 60 mounted within a tube recess 62 in the down tube 34, asexplained below in more detail.

As best seen in FIG. 4, the motor mount 40 includes a down tube mount 64coupled to the down tube 34, a seat tube mount 66 coupled to the seattube 38, and a chainstay mount 68 coupled to the chainstays 44. Theillustrated down tube mount 64 and seat tube mount 66 are welded to thedown tube 34 and seat tube 38, respectively, but any suitable connection(e.g., bonding, fastening, or unitary construction) will suffice. Theillustrated chainstay mount 68 comprises a pivot mount 70 for pivotallyconnecting the motor mount 40 to the chainstays 44 using a pivot shaft72.

The motor mount 40 further includes a side brace 74 connecting the downtube mount 64 to the chainstay mount 68 along the left side of theelectric motor 52. As best shown in FIGS. 3-4, the side brace 74 ispositioned to structurally and visually extend from the down tube 34directly toward the chainstay mount 68. As shown in FIG. 5, the rightside of the motor mount 40 does not include a side brace 74 and iscompletely open to facilitate insertion and removal of the electricmotor 52 from the motor mount 40.

Referring to FIGS. 3 and 4, the motor mount 40 further includes an uppersupport 76 connecting the down tube mount 64 with the seat tube mount66, a rear support 78 connecting the seat tube mount 66 with thechainstay mount 68, and a lower support 80 connecting the down tubemount 64 with the chainstay mount 68. As illustrated in FIGS. 3, 4, and6, the upper support 76 includes an upper flange 82 aligned with thecentral plane 26 and including a flange opening 84 adapted to receiveone of the mounting studs 54 in order to facilitate attachment of theelectric motor 52 to the motor mount 40 by the mounting nuts 55.Similarly, the lower support 80 includes a lower flange 85 aligned withthe central plane 26 and including two flange openings 84 adapted toreceive two of the mounting studs 54 in order to facilitate attachmentof the electric motor 52 to the motor mount 40. As explained above andillustrated in the drawings, the combination of the down tube mount 64,the upper support 76 the seat tube mount 66, the rear support 78, thechainstay mount 68, and the lower support 80 provides complete enclosureof the electric motor 52 along the central plane 26 of the bicycle 20.This arrangement provides structural integrity to the bicycle frame 30and also helps to protect the electric motor 52 from damage that couldbe caused by impact of the bicycle 20 with other objects (e.g., rocks orlogs). This arrangement also utilizes the electric motor 52 as astressed member to further improve the strength and rigidity of thebicycle frame 30.

As illustrated in FIGS. 3-5 and further explained above, the structuralarrangement of the motor mount 40 results in an upper left opening 86, alower left opening 88, and a right opening 90. These openings are fittedwith an upper left cover 92, a lower left cover 94 and a right cover 96,respectively. Each of the upper support 76, lower support 80, and rearsupport 78 includes threaded openings 98 for receiving threadedfasteners 100 that attach the covers to the motor mount 40. The coversprotect the electric motor 52 from damage and debris infiltrating theelectric motor 52.

Referring to FIG. 3, the illustrated battery 60 includes an upperbattery mount 102 and a lower battery mount 104 that facilitatessecuring the battery 60 to the bicycle frame 30 at an upper frame mount106 and a lower frame mount 108, respectively. When attaching thebattery 60 to the frame 30, the lower battery mount 104 is first engagedwith the lower frame mount 108 with the battery 60 in a partiallyattached position, as shown in FIG. 7. The battery 60 is then pivotedupwardly toward the frame 30 to a fully attached position, as shown inFIG. 8 and described below in more detail.

The lower battery mount 104 and lower frame mount 108 define a pivotinterface between the battery 60 and the frame 30. In the illustratedembodiment, the lower battery mount 104 comprises an eccentric boss 110adapted to engage the lower frame mount 108. In the embodiment shown inFIGS. 9 and 10, the eccentric boss 110 comprises an elongated shafthaving a cam profile with a low point 112 defining a first boss width W1and a high point 114 defining a second boss width W2 larger than thefirst boss width. As the battery 60 is pivoted from the partiallyattached position of FIG. 7 to the fully attached position of FIG. 8,the cam profile of the eccentric boss 110 will be rotated with thebattery 60 to present different profiles of the eccentric boss 110 tothe lower frame mount 108, as described below in more detail.

The illustrated lower frame mount 108 defines a depression in the formof a slot 116 that is dimensioned to receive the eccentric boss 110.With specific reference to FIGS. 9 and 10, the slot 116 has a width thatis dimensioned to easily receive the first boss width W1 of theeccentric boss 110. This is the orientation of the eccentric boss 110that will be presented to the lower frame mount 108 when the battery 60is in the partially attached position of FIGS. 7 and 9. As the battery60 is rotated to the fully attached position, the cam profile of theeccentric boss 110 is rotated such that the second boss width W2 of theeccentric boss 110 is presented to the slot 116 of the lower frame mount108, thereby wedging the eccentric boss 110 in the lower frame mount108, as shown in FIGS. 8 and 10. In order to facilitate thisinterference fit, the lower frame mount 108 is resilient (e.g., madefrom a resilient material such as polyurethane or resiliently mounted,such as spring-biased). By virtue of this arrangement, the lower batterymount 104 will be held securely to the lower frame mount 108 withreduced likelihood of any rattling occurring due to shocks orvibrations. In addition, the resilient slot 116 configuration of thelower frame mount 108 will inherently accommodate slight differences inbattery 60 lengths. It should be understood that the positions of theeccentric boss 110 and depression could be reversed (i.e., thedepression could be positioned on the battery 60 and the eccentric boss110 could be positioned on the frame 30). In addition, the eccentricboss 110 could be made of a resilient material instead of or in additionto the lower frame mount 108.

As best seen in FIGS. 7-8 and 11-12, the upper battery mount 102comprises a battery hole 118 extending all the way through the battery60, and the upper frame mount 106 includes tube holes 120 through theleft and right walls of the down tube 34 adjacent an upper end of thetube recess 62. With the battery 60 in the fully attached position ofFIG. 8, the battery hole 118 of the upper battery mount 102 will bealigned with the tube holes 120 of the upper frame mount 106, and abattery mounting pin 122 can be inserted through the aligned tube holes120 and battery hole 118 to secure the battery 60 in the fully attachedposition. In the illustrated embodiment, one of the tube holes 120 isthreaded and an end of the battery mounting pin 122 is similarlythreaded to secure the mounting pin in place.

With specific reference to FIGS. 3, 7 and 8, the illustrated bicycle 20further includes a rock guard 124 secured to and removable from a lowerend of the battery 60. The rock guard 124 includes a forked end 126adapted to fit on opposing sides of the lower battery mount 104. In theillustrated embodiment, the forked end 126 of the rock guard 124 issecured to the battery 60 by the same battery fastener 128 that securesthe eccentric boss 110 to the battery 60, as best shown in FIG. 3. Therock guard 124 further includes two threaded openings (not shown) facingthe battery 60 and adapted to receive fasteners (not shown) that can beinserted through holes in the battery 60 and threaded into the threadedopenings 98 in the rock guard 124 to further secure the rock guard 124to the battery 30. By virtue of this arrangement, the rock guard 124provides protection to the lower end of the battery 60 and can be easilyreplaced if damaged.

The battery 60 further includes a battery control panel 130 thatfacilitates control of the operation of the battery 60, best seen inFIG. 13. Specifically, the battery control panel 130 includes a powerbutton 132, a plus button 134 and a minus button 136. These buttons canbe used to power the battery 60 on and off and also to select differentmodes of the battery 60. The battery control panel 130 further includesa series of perimeter lights 138 that indicate the battery charge.

Referring to FIG. 14, the battery 60 further includes a batteryconnector 140 on the left side of the battery 60 near the lower batterymount 104. The illustrated battery connector 140 can be used both tocharge the battery 60 (e.g., with an appropriate charger, not shown) andalso to provide connection to the electric motor 52 via a motorconnector 142 wired to the electric motor 52. The illustrated motorconnector 142 includes an overmolded housing 144 that fits into and isflush with the surrounding surfaces.

The illustrated bicycle 20 further includes a speed sensor 146 securedto an inner face 148 of the left rear wheel 24 support, as illustratedin FIG. 15. The speed sensor senses the rotation of the rear wheel 24,and this information can be used to calculate the speed of the bicycle20. By virtue of this positioning, the speed sensor 146 is protectedfrom damage and is further not visible from the left side of the bicycle20, thus improving aesthetics of the bicycle 20.

Referring to FIG. 16, the inside surface of the right cover 96 includesan integral cable channel 150 that facilities routing of a cable throughthe motor mount 40. More specifically, with the right cover 96 securedto the motor mount 40, the cable channel 150 will be positioned againstthe electric motor 52, thereby creating a substantially enclosedpassageway. With this substantially enclosed passage way, a cable orhousing can be inserted into the passage way from the down tube 34 (seearrows in FIG. 16) and pushed until it exits adjacent the chainstaymount. This arrangement avoids the need to remove the right cover 96when threading a new cable or housing through the motor mount 40.

Various features and advantages of the invention are set forth in thefollowing claims.

The invention claimed is:
 1. A bicycle comprising: front and rearwheels; a frame supported on the front and rear wheels and including aframe mount; a battery including a battery mount engaged with the framemount, wherein one of the battery mount and the frame mount includes adepression and the other of the battery mount and the frame mountincludes a boss positioned in the depression, the depression designed toreceive the boss at multiple locations to accommodate slight differencesin a length of the battery, and wherein the depression comprises a slotand the slot comprises a resilient material to securely hold the boss.2. A bicycle as set forth in claim 1, wherein the boss comprises aneccentric boss.
 3. A bicycle as set forth in claim 2, wherein theeccentric boss has a first boss width that is insertable into thedepression when the battery is in a first orientation, and the bossfurther has a second boss width larger than the first boss width andcreating an interference fit with the depression when the battery is ina second orientation, wherein at least one of the boss and thedepression is resilient in order to accommodate the interference fit. 4.A bicycle as set forth in claim 1, wherein the battery mount ispositioned adjacent one end of the battery, wherein an opposite end ofthe battery includes an opening, and wherein the bicycle furthercomprises a mounting pin positioned through the opening and through aportion of the frame to secure the opposite end of the battery to theframe.
 5. A bicycle as set forth in claim 4, wherein a distance from theopening to the battery mount defines the length of the battery.
 6. Abicycle as set forth in claim 1, wherein the battery mount comprises theboss and the frame mount comprises the depression.
 7. The bicycle ofclaim 1, wherein the depression defines an opening configured to receivethe boss, and wherein one of the battery and the frame at leastpartially encloses the opening.
 8. The bicycle of claim 7, wherein thebattery at least partially encloses the opening.
 9. A bicyclecomprising: front and rear wheels; a frame supported on the front andrear wheels and including a frame mount; a battery including a batterymount engaged with the frame mount, wherein one of the battery mount andthe frame mount includes a depression and the other of the battery mountand the frame mount includes an eccentric boss positioned in thedepression, wherein the eccentric boss has a first boss width that isinsertable into the depression when the battery is in a firstorientation, and the boss further has a second boss width larger thanthe first boss width and creating an interference fit with thedepression when the battery is in a second orientation, wherein thedepression defines an opening configured to receive the boss, whereinone of the battery and the frame at least partially encloses theopening, and wherein at least one of the boss and the depression isresilient in order to accommodate the interference fit.
 10. A bicycle asset forth in claim 9, wherein the battery mount and the frame mountdefine a pivot interface between the battery and the frame such that thebattery is pivotable relative to the frame from the first orientation tothe second orientation.
 11. A bicycle as set forth in claim 9, furthercomprising a front fork supported by the front wheel, wherein the frameincludes a head tube rotationally coupled to the front fork and a downtube extending from the head tube, and wherein the frame mount isdisposed within a recess in the down tube.
 12. A bicycle as set forth inclaim 9, wherein the battery mount is positioned adjacent one end of thebattery, wherein an opposite end of the battery includes an opening, andwherein the bicycle further comprises a mounting pin positioned throughthe opening and through a portion of the frame to secure the oppositeend of the battery to the frame when the battery is in the secondorientation.
 13. A bicycle as set forth in claim 9, further comprising aguard removably coupled to the battery.
 14. The bicycle of claim 13,wherein the guard includes a forked end engaged with opposite sides ofthe battery mount.
 15. The bicycle of claim 9, wherein the battery atleast partially enclose the opening.
 16. A bicycle comprising: front andrear wheels; a frame supported on the front and rear wheels andincluding a frame mount; a battery including a battery mount engagedwith the frame mount, wherein one of the battery mount and the framemount includes a depression and the other of the battery mount and theframe mount includes a boss positioned in the depression, the depressiondesigned to receive the boss at multiple locations to accommodate slightdifferences in a length of the battery, wherein the boss comprises aneccentric boss, wherein the eccentric boss has a first boss width thatis insertable into the depression when the battery is in a firstorientation, and the boss further has a second boss width larger thanthe first boss width and creating an interference fit with thedepression when the battery is in a second orientation, and wherein atleast one of the boss and the depression is resilient in order toaccommodate the interference fit.
 17. A bicycle comprising: front andrear wheels; a frame supported on the front and rear wheels andincluding a frame mount; a battery including a battery mount engagedwith the frame mount; a guard removably coupled to the battery, whereinthe guard includes a forked end engaged with opposite sides of thebattery mount, wherein one of the battery mount and the frame mountincludes a depression and the other of the battery mount and the framemount includes an eccentric boss positioned in the depression, whereinthe eccentric boss has a first boss width that is insertable into thedepression when the battery is in a first orientation, and the bossfurther has a second boss width larger than the first boss width andcreating an interference fit with the depression when the battery is ina second orientation, wherein the depression defines an openingconfigured to receive the boss, and wherein one of the battery and theframe at least partially encloses the opening.